Continuous motion product selection and grouping system

ABSTRACT

A product selection and grouping system for the metering, selection, grouping and accumulation of varying size and/or configuration products into packs for packing in a substantially continuous motion operation is provided. The product selection and grouping system includes a metering station that receives the products in a substantially continuous line of flow from a product infeed, and meters the line of products to selectively form a series of spaces therebetween. The metered products are formed and fed to a product grouping conveyor in groups of sets a selected number of products, and are engaged by laning flights of a laning unit, which transfer the product groups to selected ones of a series of lanes defined along the product grouping conveyor. The groups of products are accumulated for transfer to a downstream packing machine.

CROSS REFERENCE TO RELATED APPLICATIONS

The present Patent Application is a continuation of previously filed,co-pending U.S. patent application Ser. No. 14/315,812, filed Jun. 26,2014, which is a formalization of previously filed U.S. ProvisionalPatent Application Ser. No. 61/957,308, filed Jun. 28, 2013 and U.S.Provisional Patent Application Ser. No. 61/845,393, filed Jul. 12, 2013by the inventors named in the present Application. This PatentApplication claims the benefit of the filing date of these cited PatentApplications according to the statutes and rules governing provisionalpatent applications, particularly 35 U.S.C. §119(a)(i) and 37 C.F.R.§1.78(a)(4) and (a)(5). The specification and drawings of the patentapplications referenced above are specifically incorporated herein byreference as if set forth in their entireties.

FIELD OF THE INVENTION

The present invention generally relates to product packaging systems,and in particular to a system and method for the metering, selection,grouping and segregation of products into lanes to create product packsfor packing by a downstream packaging machine or system.

BACKGROUND OF THE INVENTION

In recent years, as an alternative to conventional beverage or liquidpackaging such as bottles and cans, “aseptic bricks” or similarsubstantially rectangular packages, such as juice boxes, pouches, or thelike, have become increasingly popular. Such aseptic brick type packagescan include a foil or paperboard tube or sleeve filled with a liquid orsemi-liquid materials, such as juices or other beverages, or flowablebulk materials, the ends of which are then sealed to form a lightweight,disposable container. Such aseptic bricks or containers further oftenare packaged in groups such a four packs, six packs, eight packs, tenpacks, etc., in which the generally rectangular or square shaped bricksare placed side-by-side in rows and typically are shrink wrapped orotherwise banded together for shipment and/or sale.

The generally square or rectangular configuration of aseptic bricks anduse of paperboard or other generally compressible materials, which alsooften are coated with a wax or other sealing materials, can createproblems for the efficient automated packaging of such aseptic bricks orcontainers. Typically, the aseptic bricks are fed from the filling andsealing equipment, in which these containers are filled with liquid orother flowable materials and sealed, are fed in a continuous line orstream of products, wherein they can tend to become tightly compacted orcompressed together in an end-to-end abutting arrangement, particularlyat higher production speeds. Since the sides or ends of the bricksgenerally are flat, there typically are little or no gaps between theaseptic bricks, whereby conventional selectors, such as star wheels, canengage and separate or segregate the products into groups or sets asneeded for packaging, as can be done with bottles or cans having arounded or cylindrical cape.

As a result, conventional selector systems for the handling of asepticbricks or similar packages often will utilize intermittent or stop/startmotions to try to create some separation between the bricks. Forexample, some selector systems or units receiving bricks in continuousline will attempt to slow or break the movement of the bricks byclamping the sides of the bricks and then indexing or indexing thebricks to another position for discharge into separate lanes. Suchstop/start motions are repeated to form a queue of separated bricks thatcan then be intermittently fed to a packaging machine individually or bygroups of, for example, six to twelve bricks. Such indexed, intermittentfeeding motions generally are used to reduce incidents of jamming orbunching of the bricks, but they also correspondingly reduce cycle timefor the feeding and packaging of the bricks, which accordingly can limitproduction rates for packaging these aseptic bricks. In addition, anaccumulation conveyor, generally having a length that is dependent onthe laning operation of the bricks, further is needed to separatelymaintain the bricks for feeding into a separate intermittent groupingunit prior to the bricks being fed into the packing machine.

Still further, the size and generally rectangular shape or configurationof most aseptic bricks, creating flat surfaces that are generally placedin an edge-to-edge abutment, as well as the use of waxes or othersealing materials on such surfaces, also can lead to problems with thecontrol of the bricks, especially when there is a change in velocity,such as a stop/start or other intermittent movement of the brickswherein the speed of the bricks is increased to try to create a seriesof gaps or spaces as needed to enable engagement by conventionalselector systems or devices. Such stopping and starting movementsfurther can result in tipping or undesirable shifting of the bricks,especially for taller or elongated bricks or containers, which problemcan be compounded by the drag exerted by the waxy surfaces of thebricks, as well as the limited points or areas of engagement of thebricks by most conventional selector mechanisms.

Accordingly, it can be seen that a need exists for a system and methodfor the metering, selection and grouping of aseptic bricks or other,similar containers into product groups for introduction into a productpackaging machine, which enables the packaging of such an aseptic bricksor similar containers at increased rates and/or without disrupting thesubstantially continuous motion of the aseptic bricks or containers, andwhich addresses the foregoing and other related and unrelated problemsin the art.

SUMMARY OF THE INVENTION

Briefly described, the present invention relates to a system and methodfor the metering, selection, and grouping of products such as “asepticbricks” or other, similar products into desired size product groups foraccumulation into product packs of a desired size and transfer to apackaging or packing machine. For example, the products can includebricks or other containers having substantially rectangularly or squareshaped configurations and can be received in a substantially continuousline from an upstream filling system or assembly, with the productsbeing moved along a path of travel along a product input conveyor insubstantially end-to-end abutment with one another. It will, however, beunderstood that other types of containers or products having other,varying configurations, also can be processed through the system andmethod of the present invention.

As the bricks or products are fed into the product selection andgrouping system of the present invention, they will pass through aninitial, metering station at an upstream end of the product selectionand grouping system. The metering station generally will include aseries of guides defining a substantially arcuate, curved or serpentinepath travel of the bricks therethrough. As the bricks enter the meteringstation, they typically are engaged by and/or will pass about a meteringwheel, which causes an initial separation between adjacent or abuttingsides of the bricks to reduce line pressure of the incoming line ofbricks and help create or produce gaps between the abutting edges orsurfaces of the bricks. As the bricks continue around a second portionof their path of travel through the metering station, they can beengaged by fingers of a gapping wheel.

In one embodiment, the gapping wheel can have a series of fingersarranged at a desired spacing. In other embodiments, the gapping wheelcan include a series of extensible fingers that can be moved intoengagement with the line of bricks. For example, the fingers can extendor project from a series of articulating and/or adjustable lugs that canengage one or more cam tracks as the gapping wheel is rotated forguiding movement of the lugs and their fingers toward and/or away fromthe bricks. Movement of the lugs can be selectively controlled toincrease the gap size of the gaps or spaces created between the bricksto accommodate different sizes or configurations of bricks or otherproducts and/or varying product groupings. The fingers of the gappingwheel will engage and/or can be extended into the initial gaps or areasof separation between the incoming bricks, so as to foam spaces of adesired gap size or amount between each brick, while also holding linepressure within the flow of bricks as the bricks are conveyed about thesecond portion of their path of travel through the metering station. Asa result, a gapped flow of bricks can be provided, which further canhelp enable feeding of the bricks in timed positions or at a meteredrate as needed or desired.

As the spaced bricks move along a third section of their path of travelthrough the metering station, they will be engaged by fingers orprojections of a grouping or transfer wheel. The grouping wheel can havea reduced number of lugs, projections or fingers, which can be set at aspacing to selectively enter the spaces between a desired or set numberof bricks, for example, entering the line of bricks between everysecond, third, fourth, fifth or sixth product. The grouping wheelfurther can be run at varying rates with the movement of its fingerstimed to enter and separate the bricks into various groups or numbers ofproducts. The grouping wheel also typically can be run at a faster ratethan the gapping wheel so as to gather and transfer the products insubstantially compacted, back-to-back groups to a product groupingconveyor, which generally will be running at substantially the samespeed as the grouping wheel so as to maintain the stability of theproduct groups.

The product grouping conveyor will be formed with a series of lanes,i.e., two to three lanes, although more or fewer lanes can be used andwill be positioned adjacent the downstream or discharge end of themetering station. The groups of products will be selectively receivedwithin these lanes and moved toward an accumulation and discharge pointat the downstream or discharge end of the product grouping conveyor. Inaddition, a laning unit will be provided along the product groupingconveyor, including a series of laning flights arranged in groups basedupon a number of lanes into which the product groups are to beseparated. For example, if the product groups are to be separated into 3lanes of the product grouping conveyor, the laning flights can bearranged in groups of three. Each laning flight also will include aflight plate or product engaging element, typically having asubstantially L-shaped construction including a leading finger orforward section against which a foremost or leading brick of a group ofbricks is received and engaged as the groups of bricks are fed from themetering station, and a horizontal pusher plate or base that engages theside edges of the product group. The flight plates further are mountedalong brackets or arms, which in turn are each mounted on a laterallymovable carriage. The support aims or brackets of the laning flights ofeach group or set of laning flights further can be of different lengths,whereby the groups or sets of bricks or products engaged thereby will bemoved to different distances or lengths across the product groupingconveyor as needed for selectively placing the product groups into eachof the different lanes of the product grouping conveyor.

The laning unit additionally generally will include one or moreconveying mechanisms extending in a substantially elliptical path aboutthe body of the laning unit and carrying a series of spaced guide rodsalong which the carriages of each of the laning units are mounted. Aseries of cam tracks also are formed about the laning unit body, each ofthe cam tracks being selectively engaged by different ones of the laningflights of each group or set of laning flights for controlling thedifferent, varying movements of the laning flights across the productgrouping conveyor.

As the laning flights are conveyed about their path of travel in timedrelation with the feeding of the groups of products to the productgrouping conveyor by the metering station, the cam rollers of thecarriages of the laning flights also move along their corresponding orassociated cam tracks. As a result, as the laning flights are movedlongitudinally along the path of travel of the product groups along theproduct grouping conveyor, they also are moved transversely intoengagement with their selected groups of products, so as to move theproduct groups laterally across the product grouping conveyor by adistance sufficient to place each of the product groups into a selectedor corresponding lane. Once each group of products is transferred to itsselected lane of the product groping conveyor, its associated laningflight will be retracted out of engagement with its product group. Aseach product group is released by its laning flight, it will beaccelerated downstream due to the product grouping conveyor generallybeing moved at a faster rate or speed. The upstream or outermost groupsof products typically are released by their laning flights earlier thanthe closer or downstream product groups, the movement of which also canbe slowed or slightly delayed by the engagement with their associatedlaning flights, to enable each of the groups of products to catch up orotherwise be moved into substantially aligned arrangement or pack at atransfer or dead plate at the discharge end of the product grouping andconveyor. Thereafter, the assembled packs can be transferred to apackaging or packing machine product.

Various features, objects, advantages, and aspects of the presentinvention further may be set forth or will become apparent to thoseskilled in the art upon consideration of the following detaileddescription, when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view schematically illustrating the product selectionand grouping system according to one embodiment of the presentinvention.

FIG. 2 is a plan view schematically illustrating the selection andgrouping of the products according to the principles of the presentinvention.

FIG. 3 is a perspective view of the product selection and groupingsystem of FIG. 1, illustrating the laning and transfer of the productsfor feeding to a downstream packaging or packing machine.

FIG. 4 is a perspective view of the product selection and groupingsystem of FIG. 1.

FIG. 5 is a perspective view of an alternative embodiment of themetering station.

FIG. 6 is a plan view of an additional, alternative embodiment of thegapping wheel for use in the product selection and grouping systemaccording to the principles of the present invention.

FIG. 7 is a plan view of modification or alternative configuration ofthe gapping wheel as illustrated in FIG. 6, wherein the gapping wheellugs are articulable between extended and retracted positions forgrouping the products.

FIGS. 8A-8C illustrate still a further alternative configuration orembodiment of the gapping wheel such as illustrated in FIG. 6, whereinmovement of the lugs can be selectively controlled to form spaces have adesired gap size between the products.

FIGS. 9A-9C illustrate various example arrangements or groupings of thelugs of the gapping wheel of FIGS. 8A-8C, to enable formation of productgroups of varying sizes and/or arrangements.

It will be understood by those skilled in the art that the drawingsaccompanying the present disclosure are included to provide a furtherunderstanding of the present disclosure and are incorporated in andconstitute a part of the specification illustrating various aspects,features and advantages and benefits of the present disclosure andinvention, and together with the following detailed description, serveto explain the principals of the present invention. In addition, thoseskilled in the art will understand that according to common practice,various features of the drawings discussed below are not necessarilydrawn to scale, and that dimensions of various features and elements ofthe drawings shown therein or discussed below are provided simply asexamples and are not to be construed as limiting the scope of thepresent invention, and further that the drawings and features thereofmay be expanded or reduced or moved to exploded positions in order tomore clearly illustrate the principles and embodiments of the presentinvention as set forth in the present disclosure.

DETAILED DESCRIPTION

Referring now to the drawings in which like numerals indicate like partsthroughout the several views, FIGS. 1-4 illustrate an example embodimentof a product selection and grouping system 10 according to theprinciples of the present invention. The product selection and groupingsystem 10 is shown in the figures as being used with substantiallysquare or substantially rectangular shaped products P, although it willbe understood by those skilled in the art that various otherconfigurations or product shapes also can be used, including round,cylindrical, or multi-sided products. As one example, the products P caninclude aseptic bricks, or other, similar products typically formed froma foil, paperboard, or other similar compressible materials, and withsuch bricks or containers typically having substantially flat sidesurfaces. The products further can be fed in an end-to-end, abuttingrelationship from a filling system or machine, such as a form-fill andseal type machine or other upstream product filling equipment. Theproduct selection and grouping system 10 further can reconfigured asneeded for selecting and grouping products into different product groupformats by the use of change parts, variation of conveying and/ormetering speeds, as well as by varying the length of the productselection and grouping system as needed or desired.

As illustrated in FIG. 1, the products P generally are received at anupstream end 11 of the product selection grouping system 10, generallybeing fed as a substantially continuous line or flow of products 12along a product infeed 13. The product infeed generally can include aconveyor such as a belted or chain conveyor, or other, similar conveyingmechanisms, as will be understood by those skilled in the art. The line12 of products P generally will be received in an edge-to-edge abuttingrelationship in a substantially continuous line or flow of productsalong an infeed path of travel, indicated by arrow 14, into a meteringstation 17 located at the upstream end 11 of the product selection andgrouping system 10, as indicated in FIGS. 1-4.

As shown in FIGS. 1 and 3, the metering station 17 generally includes aframe 18 including a series of substantially arcuate guides 19A-19C thatdefine a substantially curved, arcuate or serpentine path travel,indicated by arrows 21A-21C. The guides 19A-19C generally are shown ascurved plates or rails having guide faces 22A-22C along which the flowor line 12 of products P will be moved so that the line of products isredirected along the path of travel 21A-21C through the meteringstation. The guides further typically will be formed from asubstantially nonstick, nonskid or reduced friction material to preventbinding or drag of the products as the products are moved along theirpath of travel 21A-21C through the metering station 17. For example, theguides 19A-19C can be made from a polished metal such as stainlesssteel, or can be made from a synthetic or plastic material such asDelrin® or other, nonstick, reduced friction material.

As further shown in FIGS. 1, 3 and 4, the metering station also caninclude a metering wheel 25 (or, as indicated in FIGS. 3-4, a pair ofmetering wheels, depending on product size and configuration). Themetering wheel 25 can be formed from a non-stick or reduced frictionmaterial, and can be a substantially free-rotating or idler type wheelthat rotates about an axle 26 as the products are fed along theirinitial path of travel 21A through the metering station 17, as shown inFIG. 1. As the line 12 of products P engages and is guided around thefree-rotating metering wheel 25, as indicated in FIG. 1, initial gaps oropenings 27 generally will be formed in the line of products, betweenthe outside edges thereof. Such gaps 27 thus cause an initial break orseparation in the edge-to-edge abutment between the incoming productsand help to reduce line pressure between the products, withoutsubstantially disrupting or causing a delay in the flow of products intothe metering station.

In addition, the diameter of the metering wheel 25 can be varied asneeded to create varying desired size initial gaps or openings 27between the products of the incoming line of products, such as forfeeding and metering different sizes of products passing through themetering station. The metering wheel also can be driven by a motor orsimilar drive as needed to form the required size gaps and to help movethe line of products through the metering station, and can furtherinclude a frictional or gripping material that facilitates theengagement and movement of the products by the metering wheel. Forexample, for larger or heavier products, the metering wheel could bedriven by a drive motor, or linked via a drive belt, chain, or otherlinkage to a motor or drive for the other driven elements of themetering station, and can be covered with a rubberized or otherfrictional or tacky coating or have a knurled, roughened or otherwisetextured surface to help provide a positive engaging contact or grippingengagement between the metering wheel and the products entering themetering station for creating the desired size gaps therebetween withoutsubstantially delaying or otherwise adversely impeding the flow ofproducts. Still further, the metering wheel could be replaced with oneor more belts, chains or similar mechanisms, as shown at 25′ in FIG. 5,which guide the line of products along their curved or arcuate path21A-21B to form the gaps 27 therein.

As shown in FIGS. 1-4, as the gapped line of products proceeds along asecond portion 21B of its path of travel through the metering station17, the products further will be engaged by a series of fingers, lugs orprojections 28 that are rotated or carried into engagement with the gapsor areas of separation 27 between each of the products by a gapping orpaddle wheel 29. The gapping wheel generally will be formed from anonstick or nonskid material, mounted on a rotating drive shaft or axle31 and being driven by a motor or similar drive system (not shown), soas to be rotated in the direction of and in timed relation with themovement of the products along section 21B (FIG. 1) of their paththrough the metering station. The fingers, lugs or projections 28 of thegapping wheel generally will be arranged at substantially equally spacedlocations about the circumference of the gapping wheel, as indicated inFIGS. 1-4, with this spacing typically based on the size and/orconfiguration of the products or bricks being fed through the meteringstation.

The gapping or paddle wheel 29 also can be formed as a change part thatcan be removed and/or changed-out to accommodate varying size and/orconfiguration products to be metered, selected and grouped through themetering station and thus the product selection and grouping system 10according to the principles of the present invention. Alternatively, thefingers or projections 28 can be formed as a series of replaceable lugsor other, similar elements that can be removed to or added from thegapping wheel at varying spacing's and/or locations as needed ordesired. This also could include pivotally mounting the fingers or lugs28 to the gapping wheel 29 in an arrangement whereby selected ones ofthe fingers or projections can be selectively retracted or extended asneeded, without having to change-out an entire gapping wheel, and/orwithout having to remove the selected fingers or lugs when not requiredfor the size and/or configuration of products being processed throughthe product selection and grouping system. As a further alternative, asshown in FIG. 5, the gapping or paddle wheel could be replaced by a beltor chain 29′, or a movable rack mechanism, with the gapping belt 29′having a series of projections or fingers 28 mounted in spaced seriestherealong so as to form the spaces between the desired/selected ones ofthe products.

The rotation of the gapping wheel 29 (FIG. 1) in timed relation with thecontinued movement of the products about the second section 21B of thepath of travel of the products through the metering station, causes thefingers 28 of the gapping wheel to be engaged within the initial gaps oropenings 27 formed in the line of products. As a result, as indicated inFIG. 1, as the gapping wheel rotates its fingers or lugs 28 into thegaps 27 between the products P, the products will become separated, soas to introduce a series of spaces or product gaps 32 of a desired sizegap or length “g” between each of the products. The engagement of thefingers in such spaces or product gaps also can help hold the linepressure of the products so as to provide a controlled, metered flow ofproducts with spaces therebetween and enable engagement of the line 12of products P by a downstream grouping wheel 35.

As further indicated in FIG. 4, as the products (i.e., the asepticbricks) are moved along their path of travel 21A-21C through themetering station, the products typically can be supported on and movedalong a static dead plate 33 mounted on and/or forming part of the frame18 of the metering station. The dead plate generally will comprise aflat sheet or plate having a substantially smooth, non-stick uppersurface 33A over which the bricks/products are moved by operation of themetering wheel, gapping wheel and grouping wheel. Alternatively, thedead plate 33 could be replaced by one or more driven discs or platesthat generally are rotated in timed relation with the rotation of thegapping wheel 29, grouping or transfer wheel 35, and/or the meteringwheel 25 (i.e., by being mounted on an axle or drive shaft thereof) tohelp reduce friction as the bricks/products are moved through themetering station. For example, as indicated in FIG. 5, a rotating ordriven plate 33 can be provided to help control and/or provide a smoothmovement of the bricks/products through the metering station, such aswhen a series of belts or other, similar metering, gapping andgrouping/transfer mechanisms are used to form the product groups.

The grouping or transfer wheel 35 (FIGS. 1-2) typically is made orformed from a nonstick, reduced friction material, in similar fashion tothe metering and gapping wheels 25 and 28, and will include a series ofspaced fingers, lugs or similar projections 36. The spacing of thefingers 36 of the grouping wheel 35 generally will be provided basedupon a desired number of products to be formed into each product groupG, as well as taking into account size and/or configuration of theproducts. For example, as shown in FIGS. 1 and 4, in the presentembodiment, a pair of generally equally spaced fingers 36 can beprovided about the circumference of the grouping or transfer wheel 35for separation of the products into groups G of products, each of whichcontains four products. It will, however, be understood that while thegrouping or transfer wheel 35 is shown in the present embodiment with apair of fingers 36, additional fingers or lugs, or even a single fingeror lug also can be used for forming greater or lesser sized productgroups as needed or desired.

In addition, the fingers 36 of the grouping or transfer wheel 35 can beformed as replaceable change parts, or can be pivotally mounted so as tobe movable between a retracted, non-engaging position and an extended orengaging position. As a further alternative, the grouping wheel itselfcan be provided as a change part, to enable the change-out and/orreconfiguration of the metering station as needed to accommodatedifferent size and/or configuration of products and/or for the formationof different size product groups; or as still a further alternative, canbe replaced by a belt, chain, or movable rack having the fingers 36mounted at spaced locations therealong. Additionally, the driving orrotation of the grouping wheel also can be controlled so as to vary thespeed or rate of rotation thereof, so that the movement of the fingersof the gripping wheel into the spaces of the line of products can betimed and/or varied to transfer varying size groups or numbers ofproducts at different desired pitches to a downstream product groupingconveyor 40.

As further shown in FIG. 1, as the products P are fed along the third orlast portion 21C of their path of travel through the metering station17, the fingers 36 of the grouping wheel 35 will be rotated intoselected ones of the spaces 32 formed in the line of products, with thegrouping or transfer wheel being driven at a rate so that the fingersselectively enter the line of products between a set number of productsand will urge the products forwardly. For example, as illustrated infigures, the fingers of the grouping wheel can enter the spaces 32formed between every fourth product so as to form a product groups G,each containing four products. The grouping or transfer wheel can bemounted on a drive shaft 38 of a motor (not shown) and can be driven ata rate slightly faster than the movement of the line of products throughthe metering station so that the products of each group G of productsare gathered and urged forwardly into an edge-to-edge abuttingrelationship, thus forming the groups G of products. These productgroups are moved along third section 21C of the path of travel of theproducts through the metering station to a discharge point 37 at whichthe groups of products are picked up by a downstream grouping conveyor40.

As indicated in FIGS. 1, 3 and 4, the grouping conveyor 40 generally caninclude a belt or other, similar conveying mechanism 41, typicallyhaving a substantially smooth, solid upper surface 42 on which thegroups G of products P are received. A series of guide rails or walls 43(FIGS. 1 and 4) will be provided along the longitudinal length of thegrouping conveyor 40, with the guide rails generally including varyinglength or size rails, so as to define a series of product lanes 44 alongthe product grouping conveyor 40. Each of the lanes 44 will receive aselected one of the product groups and will convey the product groups ina direction of arrow 46 towards an accumulated position 47, whereby theaccumulated product groups will be formed into a product pack 48 anddeposited on a transfer or dead plate 49 located at a discharge end 51of the grouping conveyor 40.

The conveyor belt 41 of the grouping conveyor 40 typically will bedriven by drive motor such as a servo-motor or other motor, which can belinked to the drive motors for the gapping and grouping wheels of themetering station so as to run in substantially timed movement therewith,or can be tied to a common drive system for driving all of the operativeelements of the product selection and grouping system. The groupingconveyor further typically can be run at a faster or higher rate thanthe rate of movement of the products being fed into the meteringstation, and at a rate similar to the rate of movement of the groupingwheel of the metering station for moving the groups of products awayfrom the metering station and toward accumulation into product packs 48over a reduced size or distance to provide a desired space savings,without substantially limiting or delaying the substantially continuousfeeding, metering, selection and grouping of the products into theirpacks for transfer to a downstream product packaging or packing machine(not shown).

In an alternative embodiment, as indicated in FIG. 2, the conveyor belt41 of the grouping conveyor 40 can include a series of conveyor belts,typically one for each lane 44 formed or defined across the groupingconveyor. For example, for 3 lanes, 3 conveyor belts (shown at phantomlines 41A-41C) can be provided. Each separate conveyor belt 41A-41C canbe independently operated so as to be driven at different speeds toprovide for the “catch-up” of the groups of products received on each ofthe conveyor belts at their accumulated position 47. As a furtherresult, the release of the groups of products by their associated laningflights 62 of the laning unit 60 may not need to be controlled toprovide for different release points, as discussed below, to enable themovement of the product groups into alignment for forming a product pack48.

In addition, as shown in FIGS. 1 and 4, a laning unit 60 generally willbe located along a lateral side 61 of the grouping conveyor 40. Thelaning unit 60 will include a series of laning flights 62 that aremovable into engagement with each of the product groups and are furthermovable laterally across the conveyor belt 41 of the grouping conveyor40, in a direction transverse to the direction of the longitudinal pathof travel 46 of the product groups received on the product groupingconveyor, as indicated by arrows 63 and 63′ for placement of the productgroups G within selected ones of the lanes 44 of the conveyor 40. Thelaning flights 62 generally will be arranged in sets or groups,generally according to a number of lanes into which the product groupsare to be divided. For example, in the embodiment illustrated in thefigures, the laning flights 62 are arranged in sets or groups of threelaning flights for selectively placing the product groups into 3 lanesformed along the grouping conveyor. It will, however, be understood thatthe groups of laning flights can be organized or formed with greater orfewer numbers of laning flights based upon the number of product groupsto be accumulated into each product pack 48 (FIG. 1). Thus, even thoughthe product grouping conveyor can be provided with multiple lanes, notall of the product lanes need to be used; for example, the laningflights can be organized into groups or sets having a smaller number oflaning flights than the product grouping conveyor has lanes, and witheach group or set moving along an associated or aligned one of a seriesof alternative cam tracks 78.

The laning flights 62 of the laning unit 60 further can be provided aschange parts that can be removed or substituted as needed. As indicatedin FIGS. 1 and 4, each of the laning flights generally will include anelongated flight plate or engagement member 65 and adapted to engageselected groups of products for moving the groups of products laterallyacross the product grouping conveyor. Each flight plate 65 further canhave a substantially L-shaped configuration, including a laterallyextending forward or leading finger 66 having a rear engaging face 67against which a foremost product P′ of the selected product group willbe engaged, and a second, substantially horizontally extending baseportion 68 having a substantially flat face 69 along the side surfacesof each of the products contained within the selected product group. Theflight plates of each laning flight will control and stabilize theproducts as the product groups are moved laterally/transversely acrossthe product grouping conveyor. As indicated in FIG. 4, the flight plates65 of each of the laning flights 62, also can have a reduced size orconfiguration so as to enable the flight plates to move beneath orbetween the innermost guide rails or walls 43 defining the product lanes44 of the product grouping conveyor 40. Thus, as the flight plates ofeach of the laning flights are retracted in a direction of arrow 63′,they can pass beneath these guide rails without interference whileleaving the product groups to move forwardly along their selected lanes44 of the product grouping conveyor 40 in the direction of arrow 46.

As further shown in FIGS. 1 and 4, flight plates 65 of each of thelaning flights generally are mounted on a forward end of an elongatedarm or bracket 71, which in turn is mounted on a carriage 72. Each ofthe carriages further is mounted on, supported and carried by guiderails 73, the ends of which are mounted on drive belts or chains 74(FIG. 4) of a drive system 76 of the laning unit 60. Each of thecarriages further typically includes one or more cam rollers or camfollowers 77 (FIG. 2) that engage and roll along a selected orassociated cam track 78 extending along the body 79 of the laning unit60.

As also generally illustrated in FIGS. 1 and 4, the laning unit 60 willhave a series of cam tracks 78, generally including at least one camtrack for each of the individual laning flights of each group of laningflights, or based on the number of lanes of the product groupingconveyor (i.e., for sets of 3 laning flights, there can be 3 camtracks). Each cam track can have a different configuration or pitch soas to control the depth or length of travel of its associated laningflights 62 transversely across the product grouping conveyor as neededto reach the selected product lane 44 in which the product groupsengaged by the lane flights will be deposited. The support brackets 71of the each of the flight plates 65 further can be of varying lengths orsizes depending upon the depth of length of travel for each laningflight across the product grouping conveyor. Thus, as illustrated inFIGS. 1 and 4, for example, the laning flights engaging the groups ofproducts to be placed in the outer-most or furthest lanes of the productgrouping conveyor generally will be moved across the greatest distanceor range of movement by their cam tracks, and further typically will bereleased from engagement with their selected product groups before theproduct groups engaged by the laning flights for the closest orinner-most lanes of the product grouping conveyor. The laning flightsassociated with the product groups being moved along the inner-most orclosest product lanes also can be maintained and engagement therewithfor a longer period of time or before release to facilitate the catchingup of the product groups of the outer-most lanes 44 therewith.

Alternatively, the laning unit 60 of the product grouping conveyor 40can include a series of flight plates or shuttles linked to and drivenacross the conveyor belt 41 by actuators such as cylinders or motors. Anexample of such a drive system for the flight plates 65 of the laningflights 62 is disclosed in pending U.S. published Application No.2014/0061000 A1, the disclosure of which is incorporated in its entiretyas fully set forth herein.

The laning flights generally will be arranged along the laning unitconveyor at a pitch or spacing so as to move into engagement or withselected ones of the product groups as the product groups are dischargedfrom the grouping wheel of the metering station. As the laning flightsengage their selected product groups, the cam rollers associated withwill be carriages thereof will engage and roll along the cam tracks 78,causing the laning flights to move laterally, in a direct transverse tothe longitudinal path of travel/movement of the product groupingconveyor shown by arrow 46, across the product grouping conveyor. Theproduct groups engaged thereby will thus be transferred to a required orselected lane of the product grouping conveyor. Once each group ofproducts is transferred into its selected or required lane, itsassociated laning flight can cammed back so as to release the productgroup from engagement therewith. The laning flights also can be moved ata slightly slower rate than the operation of the product groupingconveyor so that the product groups are slowed slightly while theycontinue to be maintained in engagement with their associated laningflights.

As further indicated in FIGS. 1-3, product groups generally will bereleased at different, varying intervals. For example, the laningflights for the product groups placed in the outer-most lanes 44 of theproduct grouping conveyor that are furthest from the laning unitgenerally will release their associated product groups earlier than theproduct groups being placed within the inner-most lanes of the productgrouping conveyor that are closer to the laning unit. By releasing theupstream product groups earlier than the product groups for the closeror downstream lanes, such released product groups are moved forwardly ata faster rate so as to accelerate and catch up to the other productgroups as the product groups are fed to the discharge point or end 51 ofthe product grouping conveyor 40. As a result, as indicated in FIGS. 1and 2, the product groups are assembled or accumulated into a desiredproduct pack 48, here indicated as including 3 rows of 4 products each(i.e., a twelve pack) with each pack being accumulated on a dead plateor other transfer mechanism 49 (FIGS. 1 and 4). Thereafter, the productpacks can be engaged by a transfer mechanism 85 (FIG. 3) such as a siderunning or overhead flighted lug system or other, similar transfermechanism that will move the product packs toward a downstream packingor packaging machine (not shown).

FIGS. 6-9C illustrate various additional or alternative embodimentsand/or configurations of systems 100 for selecting and forming theproducts P into product groups G, wherein the gapping wheel 29 of themetering station 17, shown in FIGS. 1-4 with a series of paddles orfingers 28, can be replaced with a lugged gapping wheel 101 having aplurality of lugs 102 mounted in spaced series thereabout as illustratedin FIGS. 6-9C. Each of the lugs 102 typically can include a body 103having a first, rear or base portion 104 and an outwardly flaring orexpanding second or forward portion 106, which define shoulders 107extending or projecting laterally on either side of a projection orfinger 108 that extends radially forwardly from the lug body.

In addition, the lugged gapping wheels 101 shown in FIGS. 6-9C, insimilar fashion to the paddle wheel configuration of the gapping wheel29 shown in FIGS. 1-4, generally will have a body 110 (FIG. 6) with adiameter “D” and/or circumference that is selected to match a size ordesired range of sizes of the products P passing through the meteringstation for collecting into the product groups G. The gapping wheel 101also can be formed as a change-part that can be readily removed andexchanged for other, different size or diameter gapping wheels, asneeded to accommodate changes in the product sizes being selected andgrouped. Upon such a change-out of the gapping wheel to accommodatedifferent size and/or configuration products, the guides 19A-19Cpositioned about the path of travel 21 of the products through themetering station also can be moved toward or away from the gapping wheelsuch as by moving fasteners 111 along slots 112, to adjust the positionor spacing of the guides 19A-19C along the path of travel 21A-21C of theproducts and with respect to the metering, gapping and transfer wheelsas needed to receive the varying size products therebetween.

FIG. 6 illustrates one example embodiment or configuration of a meteringstation 117 in which the lugged gapping wheel 101 is provided with aplurality of lugs 102 that can be mounted thereto in substantially fixedpositions spaced about the circumference of the gapping wheel. The lugs102 can be selected to accommodate varying sizes and/or configurationsof products, and further can be mounted in locations circumferentiallyspaced about the body 110 of the gapping wheel 101 to substantiallyensure that the fingers or projections 108 of the lugs will engage theline of products at the initial gaps or areas of separation formedbetween each of the products P for forming spaces having a desired gapsize “g” therebetween. Thus, the lugged gapping wheel 101 can beprovided with a series of substantially fixed lugs having separationsbetween their fingers that are selected based upon the size and/orconfiguration of the products being grouped.

In addition, the lugs 102 further can be adjustably mountable to thebody 110 of the lugged gapping wheel 101. For example, as generallyindicated in FIG. 6, the lugs 102 can be mounted to the body of thegapping wheel by one or more lug pins 113 or other releasable fasteners.The lug pins can be inserted into slots or openings 114 defined alongthe body 103 of each lug, and will further engage corresponding openingsor slots 116 formed in the body of the gapping wheel. The lug pins 113also can be provided with releasable locking mechanisms such as a springdetent, threaded connector, or other, similar releasable locking orconnecting mechanism, for securing the pins, and thus the lugs throughwhich they are extended, in desired positions and/or orientations on theupper surface of the gapping wheel. As a result, the lugs 102 can bequickly and easily changed-out and/or replaced without necessarilyrequiring a complete change-out of the lugged gapping wheel toaccommodate variations in product sizes or configurations.Alternatively, existing lugs also can be repositioned radially withrespect to the outer periphery or circumference of the gapping wheelwithout requiring replacement of the lugs in order to accommodateadditional variations or changes in the sizes and/or configurations ofthe products being selected and grouped.

FIGS. 7-9C illustrate further alternative embodiments or configurationsof the lugged gapping wheel 101 wherein the lugs 102 mounted thereon canbe selectively movable radially outwardly from the circumferenceperiphery of the gapping wheel 101. Such radially outward movement ofthe lugs can be controlled to selectively expand or create larger sizegaps or spaces 32 between the products P for entry of the lugs 36 of thetransfer or grouping wheel 35 for forming the product groups.

FIG. 7 illustrates another embodiment 117 of the metering station,including a lugged gapping wheel 101 in which the lugs 102 thereofcomprise articulable lugs that are generally movable radially outwardlyfrom a first, retracted position to a second, extended position, hereshown as moving between a minimum radius “r” and a maximum radius “R,”so as to cause the products P to spread further apart, creating gaps orspaces 32 having an expanded or extended gap size “g+” definedtherebetween. In this embodiment, each of the lugs can be mounted to thegapping wheel body along an elongated slot or groove 116 so as to enablethe radial movement of the lugs between their minimum and maximum radiuspositions as indicated by arrows 126/126′. The lug pins 113 insertedthrough the body of each lug 102 to secure the lugs to the gapping wheelfurther can include a cam roller or follower 127 mounted along a loweror bottom portion thereof and which will engage a cam track (shown atdashed lines 128 in FIG. 7) formed in a cam plate 129 mounted beneaththe gapping wheel 101.

As the cam rollers of the lug pins for each of the articulated lugs 102move along the cam track with the rotation of the gapping wheel,indicated by arrows 131, the lugs 102 and thus their fingers 108, willbe caused to move outwardly toward an extended position, such as beingmoved to a maximum radius R. As a result, the products are furtherspread apart, increasing their initial gap distance “g” to an expandedgap distance “g+”, and with the products further being supported andcontrolled as they continue along their path of movement through themetering station by engagement of the shoulder portions 107 of adjacentlugs with inwardly facing surfaces of the products P. Thereafter, as theproducts are moved toward engagement with a corresponding lug 36 of thetransfer grouping wheel 35, their cam rollers can be moved inwardlyalong the cam track so as to cause the lugs/fingers to be moved towardtheir retracted position, away from engagement with the products as thegrouping wheel lug 36 passes into a selected one of the expanded gaps 32formed therebetween, to thus form the desired size product group G asindicated in FIG. 7. In addition, as the gapping wheel lugs releasetheir products, the movement of products of each product group generallycan be slowed, allowing the products to be moved together or catch-up toform the product group. The enlarged or expanded gap sizes g+ can helpfacilitate entry of the transfer or grouping wheel lugs between theproducts for forming and transfer of the product groups to the groupingconveyor, and further can facilitate the exit of the gapping wheel lugsfrom the line of products.

FIGS. 8A-9C illustrate still a further embodiment or configuration ofthe metering station 117, in which the gapping wheel 101 is provided aseries of articulable lugs 102, that can be selectively movable. Forexample, selected ones 102A of the lugs, can be designated or selectedas master lugs and can set the spacing or size for the products groups.As illustrated in FIGS. 8A-8C, one or more master lugs 102A can beprovided at spaced locations about the circumference of the gappingwheel 101 with the remaining non-selected or intermediate lugs 102Bmounted therebetween. However, while 3 master lugs 102A are illustratedin FIGS. 8A-8C, greater or lesser numbers of such master lugs can beused, for example, as indicated in FIGS. 9A-9C. Each lug 102A/102B canbe provided with a pair of pin openings 114A/114B with the lug pin orfastener 113A/113B for each of the lugs 102A/102B being placed in adesired opening to select the number master lugs for the groups beingformed and thus define the movement thereof. For example, lug pins 113Afor the master lugs 102A can be placed within the first or outermost pinopening 114A, while the remaining or intermediate lugs 102B can besecured via fasteners 113B that are mounted within the second orinnermost pin opening 114B.

In one embodiment as illustrated in FIG. 8C, each of the lugs can besecured to the gapping wheel with its lug pin or fastener 113A/113Bhaving a cam follower 135 that can engage and be guided along a first orouter cam track 136, or a second or inner cam track 137 formed along acam plate 138 mounted beneath the gapping wheel for controlling movementof the lugs 102A/102B outwardly and in a retracting motion toward andaway from the products. For example, the lug pins 113A for the masterlugs 102A can be placed within the first or outermost pin opening 114Aso as to be aligned with and move along the first or outermost cam track136, while the remaining or intermediate lugs 102B can be secured vialug pins 113B that are mounted within the second or innermost pinopening 114B so that their cam followers or rollers engage and movealong the second or innermost cam track 136. As the gapping wheel 101 isrotated, the cam rollers or followers of the lugs 102A/102B move alongtheir respective cam tracks to control movement of the lugs towardand/or away from the products. Additional lug pin openings, and/or camplates having different contoured cam traces therealong can be provided,and/or the positions or locations of such lug pin openings about thegapping wheel also can be varied for further adjustment of the stroke ofthe lugs as needed to enable the formation of different size productgroups and/or to accommodate variations in the size of the productsbeing grouped.

As indicated in FIG. 8C, the master lugs 102A can be movable betweenfirst, retracted or minimum radius positions (r) and second, expandedmaximum radius positions (R), while the remaining intermediate ones 102Bof the lugs can be controlled so as to be maintained in a position, suchas at the minimum or an intermediate radius location, where the lugs102B can at least initially engage the products to form spaces 32B, butfurther can be moved or retracted away from the products as the lugs102A move forwardly intro their selected or associated spaces 32A. Thelugs 102A generally will be extensible or articulable between the gapsor spaces between the products by an extended distance or length asneeded to create larger or expanded size g+ gaps or spaces 32A betweenselected products of the line of products P being fed and engaged by thefingers of the gapping wheel. In conjunction with this radially outwardmovement, the intermediate lugs generally can be retracted radiallyinwardly from their spaces 32B and away from engagement with theproducts. As a result, a number of products, such as for forming aselected size product group, can be collected and/or urged together,with a single enlarged gap 32C defined between each collected group ofproducts, as indicated in FIG. 8A. In one example embodiment, thisincreased size space 32A can be about two or more times the size “g” ofan initial space or gap between the products, and can be increased basedon a number of products to be grouped (i.e., to form a 4-product group,the gap size can be 2×“g”−4×“g”).

FIGS. 9A-9C illustrate various example configurations of the master andintermediate lugs mounted to the gapping wheel 101 for forming differentsize product groups for feeding to the grouping conveyor. For example,as illustrated in FIGS. 8A-8B and 9A, three master lugs 102A can beprovided at substantially equally spaced locations about the peripheryor circumference of the gapping wheel with a series of intermediate lugs102B spaced therebetween. In the example of FIG. 9A, a series of threeintermediate lugs 102B are provided so as to create a product group Gincluding four products P. FIG. 9B illustrates an arrangement of fourmaster lugs 102A with two intermediate lugs 102B located between eachmaster lug for forming a product group G including three products P. Ina still further example, FIG. 9C illustrates the use of six master lugs102A, with an intermediate lug 102B spaced between each of the masterlugs for forming product groups including two products. A variety ofadditional lug configurations each including one or more master lugswith one or more intermediate lugs arranged therebetween also can beused, as will be understood by those skilled in the art.

In operation of the lugged gapping wheel 101 of the metering station asshown in FIGS. 6-9C, the gapping wheel generally will be rotated as theline of products enter the metering station, with the fingers 108 of itslugs 102 being moved at a rate substantially matching the incoming flowof the products. As the products move about the metering wheel 25, theproducts are caused to separate to an extent sufficient to form aninitial gap or opening 27 between adjacent side edges or surfacesthereof. As indicated in FIG. 6, in one embodiment wherein the lugs 102are not articulated or moved across the gapping wheel 101, the fingers108 of the lugs can be rotated into these initial gaps so as to engageand urge the products further along their path of travel through themetering station 117A. As the products are moved along the intermediatesection 21B of their path of travel, the movement of the lug fingerstherebetween further separates the products, forming gaps or spaces 32having a desired gap size or spacing length g.

Alternatively, one or more of the lugs 102 can be articulated or movedfurther radially between a first, retracted or minimum radius positionand a second, extended position (including moving to a maximum radiusposition) with the rotation of the gapping wheel, as illustrated inFIGS. 7-9C, to create varying size spaces or gaps, i.e., gaps having anincreased gap size g+. For example, as indicated in FIG. 7, the lugs 102can include a cam follower or roller coupled thereto and which isdirected along a cam track 127 as the gapping wheel rotates. As the camfollowers move along their cam track, the lugs are urged or movedradially outwardly causing their fingers 108 to move between theproducts as they move the products along the second or intermediateportion 21B of their path of travel through the metering station. As aresult, the products generally become further separated, increasing thegap spacing g+ of the spaces 32 defined therebetween. As the productsapproach the transfer or grouping wheel 35, the lugs can be retracted,such as by movement of their cam followers along an inwardly directedportion of the cam track, so as to move the lugs away from engagementwith the products as the products move along the third section 21C oftheir path of travel and are engaged by the grouping wheel lugs 36 andformed into the selected size product groups.

As further illustrated in FIGS. 8A-8C, in other embodiments, selectedones of the lugs 102A can be moved outwardly, so as to increase the gapsize of the spaces 32A between selected products. In addition, theremaining non-selected or intermediate lugs 102B can be retracted fromtheir spaces 32B. As a result, adjacent products between the lugs 102Acan be collected or moved together, with a single or larger space 32Cbeing defined between each such collection of products to facilitategrouping of the products and entry of the lugs or projections 36 of thetransfer or grouping wheel 35 therein.

Thereafter, the line of products P will be engaged by the lugs orprojecting fingers 36 of the transfer or grouping wheel 35. The lugs 36of the transfer or grouping wheel 35 can be arranged at differentspacings, for example, to provide a “2-up grouping” or a 3-up grouping,”with 3 spaced lugs as shown in FIG. 6. Other numbers and spacings oflugs, forming greater or lesser product groupings also can be provided.The lugs or fingers 36 of the transfer or grouping wheel are received inthe spaces or gaps defined between selected ones of the products (i.e.,every 2^(nd), 3^(rd), 4^(th) product, etc. . . . ) to form the productgroups. As the lugs of the gapping wheel rotate out of engagement withthe products, the products of each group G will be collected and urgedtogether and forwardly along the third section 21C of the path of travelby movement of the lugs of the grouping or transfer wheel lugs inengagement with a rearmost product of the group. The resultant productgroups will then be transferred to the product grouping conveyor.

The gapping wheel with fixed or articulable lugs mounted thereto, asillustrated in FIGS. 6-9C, accordingly can provide for additionalvariations in the formats or size of the product groupings being formedwithout necessarily requiring a change out or removal of the gappingwheel to accommodate some variations in the sizes of the product groupsbeing formed and/or variations in the configurations or sizes of theproducts themselves. In addition, by providing for the articulation ofthe lugs and thus the selective extensibility or movement of the fingersthereof between the products passing through the metering station,further variation in the gap sizes of the spaced gaps created betweenthe products, including between endmost products of adjacent productgroups, as well as variations between size of the product groupsthemselves can be provided. For example, all or selected ones of thelugs can be moved outwardly to a larger radius as needed to create alarger spacing or gap between the products and then retracted to avoidinterference with the grouping wheel lugs. By increasing the size of thegap between the product groups, the trajectory or speed of the productgroups being transferred or handed off by the transfer wheel to thegrouping conveyor can be substantially matched to the speed at which thegrouping conveyor is being operated, so as to facilitate a smoother,generally more consistent transition of the product groups to thegrouping conveyor.

The product selection and grouping system according to the presentinvention can be driven via a single drive unit, with the operativestations or mechanisms being linked to, as driven in conjunction witheach other via belts, chains or other, similar drive mechanisms. Thus,the system does not necessarily require specialized servo drives orcontrol mechanisms, although multiple motors also can be used and run incooperative engagement. The product selection grouping system furtherenables substantially continuous feeding of aseptic or other, similarproducts in aligned, abutting relationship, without requiringintermittent or start and stop motions or movements of the products, andfurther enables the selection and formation of such a substantiallycontinuous line of products into product groups of selected sizes ornumbers products, which thereafter can be separated into selectedproduct lanes for compilation or accumulation into a desired sizeproduct pack within a reduced space or area.

In addition, differential speed functions of operative elements of thesystem can be used to enable the maintaining, gathering and collatingthe products into groups while thereafter enabling the separated sets ofproducts to catch up to a previous set or group of products, as well asenabling the substantially automatic creation of a desired size orconfiguration product gap, and the ability to create gaps sufficient tointroduce transfer lugs between successive packs for transfer to adownstream packaging machine as needed. The product selection andgrouping system of the present invention thus provides a mechanism formetering, separating and discharging aseptic bricks or other, similarproducts and enables the discharging of such products in timed rates orfeeding, in which further can be varied by the use of simplified changeparts to create different numbers of products performing differentproduct group formats of packages to the change out of wheel or lugprofiles can be pitched, cam path profile and/or the camming of laningflights for movement into different numbers of lanes, as well as bysimple variation of conveyor speed and length of the product selectionand grouping system.

The foregoing description generally illustrates and describes variousembodiments of the present invention. However, it will be understood bythose skilled in the art that various changes can be made to theabove-discussed construction without departing from the spirit and scopeof the present invention as disclosed herein, and that it is furtherintended that all matter contained in the above description or shown inthe accompanying drawings shall be interpreted as illustrative, and notin a limiting sense. Furthermore, the scope of the present disclosureshall be construed to cover various modifications, combinations,alterations, etc., of the above-described embodiments, which shall beconsidered to be within the scope of the present invention. Accordingly,various features and characteristics of the present invention asdiscussed herein may be selectively interchanged and applied to otherillustrated and non-illustrated embodiments of the present invention.

We claim:
 1. A product selection and grouping system, comprising: a metering station receiving and directing a flow of products along a path of travel defined therethrough, the metering station including: at least one metering wheel located along the path of travel of the products, the metering wheel configured to engage and create a series of initial spaces between adjacent products of the flow of products; a gapping wheel located downstream from the at least one metering wheel and having a series of lugs spaced thereabout, the lugs engaging at least some of the initial spaces between the products as the products move along their path of travel so as to introduce product gaps between selected ones of the products for metering the flow of products, wherein at least selected ones of the lugs of the gapping wheel are selectively articulable between a retracted position and an extended position to engage the initial space between the products and form the product gaps therebetween; a transfer mechanism arranged downstream from the gapping wheel and having at least one finger movable into selected ones of the product gaps to separate a series of products from the flow of products for forming product groups; and a conveyor adjacent the metering station located in a position to receive and direct the product groups away from the metering station.
 2. The product selection and grouping system of claim 1, further comprising a dead plate extending along the path of travel, and over which the products are moved by rotation of the metering wheel.
 3. The system of claim 1, wherein the metering station further comprises a series of guides defining a substantially arcuate path of travel for the flow of products moving through the metering station.
 4. The system of claim 1, wherein non-selected ones of the lugs of the gapping wheel are retractable away from engagement with the flow of products as the selected ones of the lugs are in or are moving to their extended positions, to form the product gaps between the products.
 5. A product selection and grouping system, comprising: a metering station receiving and directing a flow of products along a path of travel defined therethrough, the metering station including: at least one metering wheel along the path of travel of the products, the metering wheel configured to engage and create a series of initial spaces between adjacent products of the flow of products; a gapping wheel located downstream from the at least one metering wheel and having a series of lugs spaced thereabout, the lugs engaging at least some of the initial spaces between the products as the products move along their path of travel so as to introduce product gaps between selected ones of the products for metering the flow of products; and a transfer mechanism arranged downstream from the gapping wheel and comprising at least one finger movable into selected ones of the product gaps to separate a series of products from the flow of products for forming product groups; a conveyor adjacent the metering station at a position to receive and direct the product groups away from the metering station; and a laning unit adjacent the conveyor on which the product groups are received, the laning unit comprising at least one laning flight movable along the conveyor with the product groups received on the conveyor and movable across the conveyor in a direction transverse to the movement of the product groups along the conveyor to engage selected product groups.
 6. The system of claim 5, wherein the conveyor comprises a series of lanes defined thereacross, and wherein the laning unit further comprises a plurality of laning flights and a series of cam tracks each engaged by an associated one of the plurality of laning flights so as to cause movement of the laning flights across the conveyor to engage and transfer the selected product groups to selected lanes of the product conveyor.
 7. A product selection and grouping system, comprising: a metering station receiving and directing a flow of products along a path of travel defined therethrough, the metering station including: at least one metering wheel along the path of travel of the products, the metering wheel configured to engage and create a series of initial spaces between adjacent products of the flow of products; a gapping wheel located downstream from the at least one metering wheel and having a series of lugs spaced thereabout, the lugs engaging at least some of the initial spaces between the products as the products move along their path of travel so as to introduce product gaps between selected ones of the products for metering the flow of products; and a transfer mechanism arranged downstream from the gapping wheel and comprising at least one finger movable into selected ones of the product gaps to separate a series of products from the flow of products for forming product groups; a conveyor adjacent the metering station at a position to receive and direct the product groups away from the metering station, wherein each of the lugs of the gapping wheel further comprises a lug pin mounted thereto for adjustably coupling each lug along the body of the gapping wheel, and wherein the lug pins of at least selected ones of the lugs engage a cam track as the gapping wheel is rotated so as to cause the selected ones of the lugs to be moved toward and away from engagement with the flow of products to selectively form the product gaps of a desired gap size between the products.
 8. A method of selecting products for grouping, comprising: receiving a series of products generally arranged in a line at a metering station and redirecting the products along a path of travel through the metering station; as the products are moved along the path of travel of travel through the metering station, forming a series of initial spaces between adjacent products; moving one or more lugs of a series of lugs radially between a retracted position and an extended position, wherein the one or more lugs are each moved between selected adjacent ones of the products and are configured to separate the adjacent products sufficient to create a series of product gaps having a desired gap size therebetween so as to define product groups each having a selected number of products, wherein selected lugs of the series of lugs are moved radially outwardly into the spaces between the selected ones of the products and non-selected lugs of the series of lugs are moved radially inwardly away from the products, such that a series of products are collected together; engaging and urging each of the product groups forwardly along the path of travel and away from a next product group; and discharging the product groups from the metering station.
 9. The method of claim 8, wherein forming the series of initial spaces comprises engaging the products with a metering wheel as the products are moved along an arcuate path of travel through the metering station to cause at least a partial separation between the products of the line of products.
 10. The method of claim 8, wherein the selected ones of the lugs are each coupled to a cam follower that engages a first cam track as the gapping wheel is rotated, and are moved toward their extended position as their cam followers are moved along the first cam track, and wherein the non-selected ones of the lugs are each coupled to a cam follower engaging a second cam track as the gapping wheel is rotated, and are moved toward their retracted position as their cam followers are moved along the second cam track.
 11. The method of claim 8, wherein discharging the product groups comprises releasing the product groups into selected product lanes at varying intervals, and accumulating the product groups to form a product pack.
 12. The method of claim 11, wherein accumulating the product groups comprises moving selected ones of the product groups released into different lanes at different rates so as to move a series of product groups into alignment.
 13. A method of selecting products for grouping, comprising: receiving a series of products generally arranged in a line at a metering station and redirecting the products along a path of travel through the metering station; as the products are moved along the path of travel of travel through the metering station, forming a series of initial spaces between adjacent products; moving one or more lugs of a series of lugs radially between a retracted position and an extended position, wherein the one or more lugs are each moved between selected adjacent ones of the products and are configured to separate the adjacent products sufficient to create a series of product gaps having a desired gap size therebetween so as to define product groups each having a selected number of products; engaging and urging each of the product groups forwardly along the path of travel and away from a next product group; discharging the product groups from the metering station; and receiving the product groups from the metering station on a product grouping conveyor and transferring the product groups to selected lanes defined across the product grouping conveyor.
 14. The method of claim 13, wherein transferring the products to selected lanes comprises engaging each product group with an associated laning flight and moving the laning flights across the product grouping conveyor by a distance sufficient to place the product groups within their selected lanes.
 15. A system for selecting and grouping products received in a substantially abutting flow of products, the system comprising: a metering station receiving and guiding the products along a substantially arcuate path of travel, including a first path section along which areas of separation are formed between each of the substantially abutting products of the flow of products, a second path section wherein a series of lugs selectively are moved into engagement with the flow of products, the lugs configured to engage the flow of products at the areas of separation therebetween to form gaps of a desired gap size between selected ones of the products; a grouping mechanism downstream from the projections and including at least one lug movable into selected ones of the gaps and urge a series of products forwardly to form product groups for discharge; a product conveyor downstream from the metering station, the product conveyor receiving the product groups discharged from the metering station and moving the product groups in spaced series along a path of travel toward an accumulation point wherein the products are accumulated into product packs; and a laning unit adjacent the product conveyor, the laning unit comprising at least one laning flight movable across the product conveyor in a direction transverse to the path of travel of the products, for transferring the products to selected lanes of the product conveyor.
 16. The system of claim 15, wherein the laning unit comprises a series of laning flights and a series of cam tracks engaged by associated ones of the laning flights for causing the lateral movement of the laning flights.
 17. The system of claim 15, wherein the metering station further comprises a series of guides defining the substantially arcuate path of travel for the line of products moving through the metering station.
 18. The system of claim 15, wherein the metering station further comprises a metering wheel located along the first path section in a position to engage and form the areas of separation between the products, and a gapping wheel downstream from the metering wheel and having a series of lugs positioned in spaced series thereabout, the lugs each including a body from which the projections extend, wherein the gapping wheel rotates the projections toward the products so as to engage at least selected ones of the areas of separation between the products to form the gaps between the products.
 19. The system of claim 18, wherein at least selected ones of the lugs are articulable between a retracted position and an extended position to engage the line of products and form the spaces therebetween, and wherein non-selected ones of the lugs are retractable away from the products when the selected ones of the lugs are in or are moving to their extended positions, to enable formation of selected ones of the gaps with an increased gap size.
 20. A method of grouping products moving in an edge-to-edge abutting relationship, comprising: receiving an incoming flow of products at a metering station and directing the products along a path of travel through the metering station; creating an initial separation between the products of the incoming flow of products; moving a series of fingers into areas of separation between at least selected ones of the products to form spaces of an expanded gap size between selected ones of the products; collecting a desired number of products together to form product groups; discharging the product groups from the metering station; receiving the product groups on a product conveyor and transferring the product groups to selected lanes defined across the product conveyor; and accumulating the product groups to form a product pack.
 21. The method of claim 20, wherein transferring the product groups comprises moving an associated laning flight into engagement with each product group and moving the laning flights across the product conveyor by a distance sufficient to place each of the product groups within their selected lanes.
 22. A method of grouping products moving in an edge-to-edge abutting relationship, comprising: receiving an incoming flow of products at a metering station and directing the products along a path of travel through the metering station; creating an initial separation between the products of the incoming flow of products; moving a series of fingers into areas of separation between at least selected ones of the products to form spaces of an expanded gap size between selected ones of the products; collecting a desired number of products together to form product groups; and discharging the product groups from the metering station, wherein discharging the product groups from the metering station comprises releasing the product groups into selected lanes of the product grouping conveyor, and moving the released product groups forwardly at a rate sufficient to move the product groups into alignment to form the product pack.
 23. A method of grouping products comprising: receiving the flow of products moving in an edge-to-edge abutting relationship at a metering station; forming gaps between abutting products of the flow of products as the flow of products is directed along a path of travel through the metering station; engaging the flow of products at selected gaps and expanding the selected gaps sufficient to form spaces of a desired gap size between selected ones of the products, wherein engaging the flow of products into at least selected gaps comprises articulating a series of lugs radially between a retracted position to an extended position wherein the lugs are extended into the gaps between the products, further separating the products to define the spaces therebetween; collecting a desired number of products together to form a series of product groups; receiving the product groups on at least one product grouping conveyor and moving the product groups transversely with respect to the at least one product grouping conveyor; and moving the product groups with the at least one product grouping conveyor and accumulating the product groups to form a product pack.
 24. The method of claim 23, wherein selected ones of the lugs are moved radially outwardly into the spaces between the selected ones of the products and non-selected ones of the lugs are moved radially inwardly away from the products, wherein a series of products are collected together with spaces having the desired gap size defined between each collected series of products.
 25. The method of claim 24, wherein the selected ones of the lugs are coupled to a cam follower engaging a first cam track as the gapping wheel is rotated, and are moved toward their extended position as their cam followers are moved along the first cam track, and wherein the non-selected ones of the lugs are coupled to a cam follower engaging a second cam track as the gapping wheel is rotated, and are moved toward their retracted position as their cam followers are moved along the second cam track.
 26. A method of grouping products, comprising: receiving the flow of products moving in an edge-to-edge abutting relationship at a metering station; forming gaps between abutting products of the flow of products as the flow of products is directed along a path of travel through the metering station; engaging the flow of products at selected gaps and expanding the selected gaps sufficient to form spaces of a desired gap size between selected ones of the products; collecting a desired number of products together to form a series of product groups; receiving the product groups on at least one product grouping conveyor and moving the product groups transversely with respect to the at least one product grouping conveyor; moving the product groups with the at least one product grouping conveyor and accumulating the product groups to form a product pack; and feeding the product groups to a series of product grouping conveyors, each defining a lane, and each moving at a different rate so as to move the product groups received thereon toward an aligned accumulated position. 